Thermostatic switch



Feb. 5, 1957 J. YOUHOUSE THERMOSTATIC SWITCH Filed Sept. 3, 1954 QLD lNvENToR @ML/lla@ ATTORNEYS United States Patent i THERMOSTATIC SWITCH Joseph Youhouse, Fairield, Conn., assignor to Casco Products Corporation, Bridgeport, Conn., a corporation of Connecticut Application September 3, i954, Serial No. 454,4

S Claims. (Cl. Z110-#137) This invention relates to thermostatic switches, and more particularly to switches for automatically controlling the circuits of electrically-heated appliances.

The invention is shown as incorporated in a domestic atiron of the steam electric type; however it should be understood that the invention is not limited to the specie disclosure set forth herein, since it has utility in connection with other articles which will be readily apparent to those skilled in the art.

One type of thermostatic switch as commonly used in electric irons comprises a pair of ilexible arms carrying cooperable contacts, one of said arms being adjustably positioned by en adjustment screw or calibration device the other arm being automatically actuated by a heat-responsive member such as a strip of bimetal or the equit'alent. ln constructing such thermostats, consideration must be given to the space available for it to occupy, and preferably the thermostat should be as small and compact as possible, since users normally preier the ilatiron to be relatively small in size. Much of the space within the casing of the ilatiron is occupied by the water reservoir or boiler, and user requirements also dictate that the amount of water which may be held at one iilling be quite appreciable, thereby to enable a large amount of ironing to be done without continually reiiliing the iron.

constructing such thermostatic switches for compactncss, the contact-carrying arms are usually made flexible and arranged side-by-side, the movable or heat-actuated arm being provided with reverse bends to enable it to clear the mounting means for the other arm and to otherwise accommodate components of the thermostatic switch.

l have discovered that the provision of such bends in the actuated7 contact-carrying arm has been the cause of defective operation and loss of accuracy in the calibration, since stresses to which the arm is subjected have had a tendency to cause straightening of the arm where it was initially bent or shaped. Thus the eliiciency and reliability ot' these thermostatic switches have been impaired.

The present invention overcomes the above disadvantage of this prior thermostat construction, and an object of the invention is to provide an improved thermostatic switch which, while easily calibrated, will be reliable as regard its calibration 'throughout an extended period of use.

Another object ot the invention is to provide an irnproved thermostatic switch as above set forth, which is extremely simple in its construction, small and compact, and economical to produce.

in accomplishing the above objects, I construct the bent contact-carrying arm which is actuated by the heatresponsive means so that it is stifiened, as by forming it transversely of its length with flanges or bent sections, such sections being in the vicinity of the bends of the arm which previously had a tendency to become straightened. The stiened sections of the arm still remain 2,780,598 Patented Feb. 5, 1957 somewhat flexible and yieldable, thereby to not intertere with proper operation of the heat-responsive means. However, the stiitening means has a stabilizing influence on the shape of the arm to such an extent that there is nrevented any 'tendency for the arm to straighten where I'l e bends are provided. Accordingly, the contact-carry arm retains its original shape throughout its useful y resulting in great stability and reliability in e calibration of thc thermostatic switch and in its operation.

Other lfeatures and advantages will hereinafter appear.

in te accompanying drawings:

F'U i is a side elevational view of a steam iron incorporating a thermostatic switch made in accordance with the invention, the switch and portions of the iron g shown in vertical section.

Fig. 2 is a detail, enlarged, showing the improved thermostatic switch in vertical section.

Fig. 3 is a perspective view of the heat-responsive cont arm of the switch shown in Figs. l and 2.

` 4 is a transverse section taken on line 4--4 of 5 is a view like Fig. 2 but showing another form ot' heat-responsive means for actuating the contact arm. The steam iron shown Fig. l comprises a sole plate 'ing above it a casing 1i within which a boiler 12 water is disposed. Attached to the top of il is a handle structure 13 by which the iron may be manipulator, Within the sole plate an electric heating coil. N is carried, for the purpose of providing h for the sole plate and boiler.

ln accordance with the present invention I provide a novel and improved thermostatic switch l5 of small and compact construction within the casing 1l, said switch being mounted on the sole plate iii and to the rear and elow the boiler 12 and being so constructed and arranged that it is reliable in its calibration and operation throughout an extended period of use.

The improved thermostatic switch 15 comprises a casing le in the form of an inverted channel, having a top wall l and side walls 13, the latter extending to and being fastened on the sole plate lil.

Within the casing i6 there is provided a heat-responsive means comprising a at member or strip i9 of high expansion metal having secured to its ends a bowed strip 26* `formed of metal which has low expansion characteristics. Carried by the central portion of the bowed member itil is an insulating button 2l adapted to engage one ot the contacts of the switch.

iv'iounted on the upper wall 17 of the casing are ilexible contact arms it?. and T23, said arms being insulatedly secured in place by rivets Zd and insulating strips and The contact arms ft2 and 23 respectively carry at their ends electrical contacts 27 and 28, and the arm ged by an adjusting screw 2 mounted in a threaded collar El@ secured to the casing i6 whereby adjustment of the switch may be effected. The screw 29 has an upwardly extending shank Si. carrying a knob 32 by which the screw may be adjustably turned, said knob being associated with a scale on the handle portion t3 oi? the iron whereby a. calibration may be established for the switch, various settings of the knob 32 corresponding to different ranges of heats suitable ior ironing different types of fabrics.

For the purpose ot making the thermostatic switch small. and compact whereby it will not require great deal space within the il of the iron, the contact arms 22 and 23- are arr'. ged toextend alongside each other with the mounting rivets Zd disposed longitudinally on the upper wall 'i7 or". the casing, and the heatfresponsive means 19, ttis disposed alongsidel of and below the Contact arms 22- and. 23, thereby to further improve the compact ar-I rangement. In carrying out such arrangement, to provide proper clearances for one of the fastening rivets 24 and for the heat-responsive means i9, 2d and the button 2l, the contact arm 23 is bent at a number of places along transverse lines, thereby to better accommodate it in the assembly without danger of short circuiting, contacting other components which might interfere with its proper movement, etc. The contact arm 23 has reverse bends 34 and and also reverse bends 36 and 37, by which portions of the arm are offset laterally from other portions to effect the desired clearances.

From a consideration of Fig. 2 it will be observed that the action of the heat-responsive means 19, 2li and the button 21 may be such as to force the contact arm 23 upward, thereby bringing the lower electrical contact 23 in engagement with the upper electrical contact 27. Any continued movement of the heat-responsive means, resulting in continued upward movement of the button 21 will result in a flexure of the lower contact arm 23, inasmuch as the upper contact 27 is immovably bacsed up by the adjustment screw 29.

An increase in the temperature of the members 19 and 20 results in lowering of the insulating button 2i, and lowering of the contact arm 23, and vice versa.

l have discovered that, as a consequence of continued operation ot thermostatic switches when made as above set forth, there is a tendency for the lower contact arm 23 to depart from its given bent shape, and when such departure occurs it upsets the calibration of the thermostat and results in improper ironing temperatures for the various settings of the knob 32. Moreover, if the departure of the contact arm 23 from its original shape is sufliciently great it may result in undue arcing and even short circuiting of the components within the switch, rendering the switch inoperative. I have discovered that this deformation or departing of the lower contact arm 23 from its given bent shape may be virtually entirely eliminated in a very simple and effective manner, and have determined that when so eliminated there is cured or obviated the difhculty as regards variance in the calibration of the thermostat and improper operation thereof as above mentioned.

Referring to Figs. 3 and 4, l effect stability of shape of the lower contact arm 23 by forming the arm transversely of its length, as by the provision of upset edge flanges 38 to effect stiifening of the arm, particularly those portions in the vicinity in the bends 3S, 3,6 and 37'. lt will be understood that the bend 34 which is adjacent the fulcrum of the arm is intended to yield or hex, and that such action has no adverse effect upon the positioning of the arm or shape of its eective length. The provision of the Bauges 38 adjacent the bends 3S, 35 and 37, however, effectively prevents straightening of the arm at the bends during its use in the thermostat, and it has been determined that an arm as thus constituted retains its original given shape throughout the useful life of the device. Thus, the initial calibration of the thermostatic switch is maintained, as well as the initial relative positions of the components, resulting in a thoroughly practical and reliable product. The provision of the side anges 38, while seemingly simple, has solved a problem which at the outset was perplexing and bafliing, since minute changes in the shape of the lower contact arm 23 were, while normally undetectable, suiicient to throw out the calibration of the thermostat very appreciably.

By the above organization I have provided an accurate and reliable thermostatic switch which is at the same time extremely simple and economical to manufacture, small in size and compact in its arrangement. The switch requires no more space than prior thermostatic switches of this type, yet is greatly superior in its performance to these prior switches.

Fig. 5 shows a modification of the invention. Components in Fig. 5 which are similar to those already described above have been given like characters. The dilerence between the switch of Fig. 5 and that of Fig. 2 resides in the heat-responsive actuating means. In Fig. 5 a high expansion strip titi is secured at its rightmost end 41 to the casing i6. At its leftmost end 42 the strip 40 has attached to it one end d3 of a low expansion strip 43a whose other end d4 abuts a bell crank #l5 carried by a pivot 46 mounted in the side walls 1d of the casing 16. The bell crank 4S has an insulating button 47 engaging the lower Contact 23 for the purpose of actuating the same. increases in the temperature of the strips iti and 43 result in clockwise turning of the bell crank 45, and lowering of the contact arm 23, and vice versa.

Variations and modifications may be made within the scope of the claims and portions of the improvements may :e used without others.

l claim:

l. A heat-responsive electric switch comprising a base; an arm formed from iiexible stock, secured to and movable with respect to the base, said arm having a contact spaced from its securement to the base and being provided with a bend between the contact and said securement, a portion of the arm being formed transversely of its length to provide a stiiened section at said bend, thereby to minimize straightening of the arm at the bend; and heat-responsive means connected with the base, engaging said arm for moving the same to operatively shift the said contact.

2. The invention as defined in claim l in which the formation of the arm transversely of its length provides n channel section with opposite side flanges on the arm.

3. A heat-responsive electric switch comprising a base; an elongate arm of sheet metal attached at one end to the base, said arm being formed transversely of its length to stiifen it and having a contact carried hy its other end, the stitened portion of the arm being bent along a transverse line; a second contact carried by the base and engageable with the contact on the arm; and heat-responsive means connected with the base and engaging the stitliened portion of the arm to actuate the same for engaging and disengaging said contacts, said stiffened arm portion being resilient and tending to minimize straightening of the arm at the bend.

4. The invention as deiined in claim 3 in which the heat-responsive means in cooling forces in the arm in a direction to engage the said contacts.

5. A heateresponsive electric switch comprising a base; an elongate arm of sheet metal attached at one end to the base, said arm being formed transversely of its length to stiien it and having a Contact carried by its other end, the stitlened portion of the arm having reverse bends along transverse lines; a second contact carried by the base and engageable with the contact on the arm; and heat-responsive means connected with the base and cngaging the stifrfened portion of the arm to actuate 'the same for engaging and disengaging said contacts, said stitened arm portion being resilient and tending to minimize straightening of the arm at the bends.

6. The invention as defined in claim 5 iu which thc arm has pairs of reverse bends all but one of which is in the stiiened portion of the arm.

7. A heat-responsive electric switch comprising a base; a spring arm secured at one end to the hase; a Contact carried by the base; a coopera-.ble contact carried by the free end of said spring arm; and heat-responsive means engaging said spring arm intermediate its ends for moving the arm to engage or to separate said contacts, said spring arm having a bend between its ends and being formed transversely of its length to provide a stiiened section in the vicinity of said bend, thereby to minimize straightening of the arm at the bend during use.

8. A heat-responsive electric switch comprising a hase; a pair of spring arms secured at one end each to the base and extending side-by-side; cooperable contacts carried by the free ends of said spring arms; and heat-responsive means engaging one of said spring arms intermediate its @nds for moving the arm closer to or further from said other arm to engage or to separa-te said contacts, said one spring arm having a bend between its ends for clearance purposes and being formed transversdy of its length to provide a stiffsned section in the vicinity of said bend, thereby to minimize straightening of the arm at the bend and resultant dispacement of the Contact.

References Cited in the le of this patent UNITED STATES PATENTS Poitfas Feb. 7, '1950 Berlyn et al May 23, 1950 Reingruber et al, May 26, 1953 Miller July 7, 1953 

